Nonlinear Milling Edge Profile for Vibration-Stable Milling Tools
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Solution Overview
Problem
Existing milling tools face challenges in achieving high surface quality and extended tool life, particularly in reducing vibrations and risk of breakage during high-speed milling operations, due to inadequate design that fails to effectively manage oscillations and vibrations.
Innovation Solution
The design incorporates a milling tool with a fir tree-shaped milling edge profile and chip space base that follows the milling edge profile, featuring non-linear progression and constant radial distance between the milling edge and chip space base, which enhances strength and stability, reducing vibrations and improving tool life.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the milling edge profile is designed with linear progression, then the manufacturing is simpler, but the tool life and stability are reduced due to increased vibrations and oscillations
Solution Approach 1:
The patent applies parameter changes by transitioning from a linear milling edge profile to a non-linear profile with specific geometric characteristics. The non-linear profile includes varying curvature radii and optimized transition zones that reduce vibrations and oscillations during milling, thereby extending tool life and improving reliability without significantly complicating the manufacturing process.
2Productivity
If the radial distance between milling edge and chip space base is variable, then the chip removal may be improved, but the structural strength and stability are reduced increasing breakage risk
Solution Approach 1:
The patent applies local quality by maintaining a constant radial distance between the milling edge and chip space base in critical regions where structural strength is required, while optimizing the chip space geometry locally to ensure effective chip removal. This localized optimization balances structural integrity with chip evacuation efficiency, reducing breakage risk while maintaining productivity.
3Manufacturing precision
If the milling edge profile follows a non-linear progression, then the surface quality and tool life are improved, but the manufacturing complexity increases
Solution Approach 1:
The patent applies spheroidality by incorporating curved transitions and varying radius profiles in the milling edge geometry. The non-linear profile features smooth curved transitions between different sections, which reduce vibrations and improve surface quality. The curvature-based design achieves enhanced manufacturing precision while keeping the manufacturing process manageable through standardized geometric features.
4Productivity
If the milling tool is designed for high-speed operation, then the productivity increases, but the vibrations and oscillations increase reducing surface quality
Solution Approach 1:
The patent applies dynamics by optimizing the milling edge profile to dynamically adapt to high-speed operation conditions. The non-linear profile with optimized curvature radii and transition zones reduces vibrations and oscillations that occur at high speeds, allowing the tool to maintain both high productivity and high surface quality. The dynamic characteristics of the profile are specifically designed to minimize resonant vibrations during rapid machining.
Data Source
AI summary
A milling tool having an operating area that is rotatable about an operating axis of rotation for milling a workpiece. The operating area has at least one milling edge extending transversely to the circumferential direction (U) of an operating axis of rotation. At least one of the at least one milling edge includes at least one milling edge portion in which a milling edge profile (P), which is defined by the radial distance (F) between the milling edge and the operating axis of rotation along the milling edge, has a non linear progression. The milling edge in the milling edge portion has a chip space, which extends radially inward toward the operating axis of rotation in relation to the milling edge. The chip space has a chip space base that follows the milling edge profile (P) at least in portions in the milling edge portion with the non-linear milling edge profile (P).